Unitary insulating housing for rocker switches

ABSTRACT

A rocker switch has a rocker housing and a cylindrical switch housing extending from the rocker housing. A switch mechanism is mounted in the switch housing and is operated by a rocker mounted at least partially within the rocker housing to pivot about an axis. The cylindrical switch housing is smaller than the rocker housing so that the switch housing can be inserted in a hole in a face to project through the hole and be located with the rocker housing abutting the face. Also the two housings are formed as integral parts of a switch body comprising a pair of moulded shells arranged on opposite sides of a plane including the axis of the cylindrical switch housing.

C Umted States Patent 1191 [111 3,732,388

Taylor 1 May 8, 1973 54] UNITARY INSULATING HOUSING FOR 3,548,131 121970 Piber ..200/168 c ROCKER SWITCHES 3,538,285 11/1970 Orts ...200/l72A X 2,847,559 8/1958 Harrin ton et a1 ..200/l67 A x [751 Invenm" Wlllm"Eric l walsall 2,430,189 11 1947 Schelh1an ..200/l67 A x gland [73]Assignee: George Turnock Limited and Henry Examiner-PI- Jones CharlesShem), London, England Attorney-Scrivener, Parker, Scrivener & Clarke[21] App! 166342 A'rocker switch has a rocker housing and a cylindricalswitch housing extending from the rocker housing. A v [30] ForeignApplication P i rit D t switch mechanism is mounted in the switchhousing and is operated by a rocker mounted at least partially July 29,1970 Great Brltam ..36,60l/70 within the rocker housing to pivot aboutan axis. The cylindrical switch housing is smaller than the rocker 12%](gl. ..200/l68 C, housing so that the Switch housing can be inserted ina d A 67 A hole in a face to project through the hole and be 1 8 locatedwith the rocker housin abuttin the face.

Also the two housings are formed as integral parts of a switch bodycomprising a pair of moulded shells ar- [56] References Cited ranged onopposite sides of a plane including the axis UNITED STATES PATENTS ofthe cylindrical switch housing.

3,412,225 11/1968 Rogers ct al. ..200/168 C 9 Claims, 4 Drawing FiguresPATENTEBHAY 13 SHEET 2 F 2 4 4 III,

28 27/ 3032 33 34 15 Maw 38 UNITARY INSULATING HOUSING FOR ROCKER hole,abuts said one side of the panel, means being provided to secure theswitch in this position.

Hitherto the usual kind of rocker switch has had the switch mechanismand the rocker mounted in a common casing of substantially rectangularshape as viewed when facing the rocker, there being an outwardlydirected flange around the front part of the casing. To mount a switchof this kind on a panel it has been practice to form a rectangular holein the panel and to push the casing through the hole from one side"until the flange abuts the panel. The advantage of the presentinvention is that the switch can be mounted in a relatively smallcircular hole in a panel, and that the size of this hole is not governedby the size of the rocker. Further, it is in general less expensive tomake a circular hole than to make a rectangular hole. Thus it ispossible to make a rocker switch which can be mounted in a hole A aninch in diameter while having a rocker threequarters of an inch or evengreater in length. Rocker switches of this kind are particularlysuitable for use for controlling accessories in motor vehicles, for itis customary to provide panels for supporting the switches for suchaccessories. Hitherto it has not been possible to use rocker switches onsuch panels, and it has been necessary to use toggle switches.

There will now be described, by way of example, one particular form ofswitch embodying the invention and primarily intended for use in motorvehicles. This switch is illustrated in the accompanying drawings, inwhich:

FIG. 1 is an exploded perspective view of the switch components,

FIG. 2 is a perspective view of an assembled switch in relation to asupport panel,

FIG. 3 is a section through the switch in the off position, and

FIG. 4 is a section through the switch in the on position.

In the drawings the switch has a body made as a moulding of a suitableplastics material such as that sold under the Registered Trade MarkDelrin. The body includes a rear portion or switch housing 1 which is oftubular shape and which is open at one end and closed at the other endby an integral end plate 2. The body also includes a front portion whichconstitutes a rocker housing 3 and which has a rectangular back plate 4,with a central circular hole leading directly into the interior of theswitch housing 1, and with a forwardly directed peripheral flange 5.That part of the switch housing 1 adjacent to the back plate 4 of therocker housing 3 is externally screw-threaded and can engage a nut 6passed over the remainder of the switch housing. The maximum diameter ofthe switch housing 1 is slightly less than half an inch. In use theswitch housing is passed through a half inch diameter hole 7 in arelatively thin panel 8, and the nut 6 is passed over the housing andbrought into engagement with the screw-threaded part thereof. When thenut 6 is tightened that part of the panel 8 bordering the hole 7 istrapped between the nut 6 and the back plate 4 of the rocker housing 3.

As shown in FIG. 1 the switch body is assembled from two components, orshells 9, which abut each other and which lie on opposite sides of acentral plane which includes the axis of the tubular switch housing 1and is parallel with the shorter sides of the peripheral flange 5 of therocker housing 3. Each shell 9 thus comprises a semi-cylindrical portionwith a hollow box-like portion 11 at one end. The shells are moulded sothat they lie on the same side of said central plane and with theirsemi-cylindrical portions co-axial. The end plates 2 of those portionsface one another and are joined by an integrally formed strap 10. Thecentral part of the strap 10 is weakened so that it can readily befolded in two during assembly. The strap 10 may be severed from the bodyafter assembly or may remain as a U-shaped component projecting from theend plate as shown in FIGS. 3 and 4. Alternatively the shells 9 may bemoulded separately.

The shells 9 are held together by a rectangular collar 12 or bezel whichis fitted around the peripheral flange 5 of the rocker housing 3. Thecollar 12 is preferably formed from the same material as that used forthe shells 9, and it may have a film of metal deposited on it by avacuum process to give it a metallic appearance. The collar 12 has anintumed flange 13 at the front which conseals the front edges of theperipheral flange 5. The collar 12 is preferably retained by frictionalone but may be arranged to snap onto the flange 5, a part of itpassing behind the back plate or entering recesses in the outer face ofthe flange. Alternatively the shells 9 may be adhesively securedtogether.

A boss 14 of approximately square cross-section projects from each ofthe semi-circular end plates 2 of the semi-cylindrical portions of theswitch housing 1, the bosses l4 abutting each other when the switch isassembled. One boss 14 carries an integral pin 15 while the other bossis formed with a complementary through hole 16. During assembly the pin15 is pushed through the holes 16 and its projecting end is cold-rivetedto hold the bosses 14 together.

A rocker 17 is a close fit within the peripheral flange 5 of the rockerhousing 3 though one end or the other projects from the housing when itis in either of its end positions. The front face of the rocker 17 isslightly concave, and the ends of the rocker 17 are slightly convex. Therocker 17 is moulded from transparent or translucent material andcontains a bulb 18 which is arranged to light when the switch is turnedon. The bulb 18 has an Edison screw cap 19 of about 3/16 of an inch indiameter. The rocker 17 is hollow and opens towards the back plate 4 ofthe rocker housing 3. The bulb 18 is housed in a carrier 20, formed froman appropriate plastics material, which fits into the central part ofthe interior of the rocker 17. The carrier 20 is in the shape of arectangular block formed with an open-ended channel in which the cap 19of the bulb 18 rests. Trunnions 21 project outwards from the block,their common axis being normal to the length of the channel, and

the sides of the rocker 17 are formed with semi-circular slots 22 whichreceive the inner portions of the trunnions 21. Outer portions of thetrunnions 21 enter aligned recesses 22 in the peripheral flange 5. Therecesses 22 extend on both sides of the central plane and can thus bereadily moulded in the two shells 9. Further the trunnions 21 can beintroduced into the recesses during assembly of the shells 9. Thearrangement is such that the rocker 17 can rock through 30, furthermovement being prevented by the ends of of the rocker l7 abutting theback plate 4 of the housing 3. A metal blade 24 projects through a slotin the carrier 20, the inner end engaging the cap 19 of the bulb 18 atthe base of the channel, and the outer part forming an operating cam.The blade 24 may be formed from brass but it is preferably formed fromsteel as the wearing properties of steel are better than those of brass.

The end contact 25 of the bulb 18 is in permanent contact with thestrip-metal contact band 26 housed in the adjacent end of the rocker.The contact band 26 is larged U-shaped, one limb engaging the contact25, the base abutting the face of the rockers interior which faces theback plate of the rocker housing, and the other limb abutting the endwall of the rocker and terminating in a contact portion which extendsover the adjacent edge of the end wall of the rocker, in a shallowrecess in that wall. During assembly the contact band 26 is pushed intothe appropriate end of the interior of the rocker 17 where it may beheld by friction or being snapped beneath lugs on the side wall of therocker, or by stops cold-riveted over the margins of the contact afterthe latter is in position.

The blade cam 24 projects rearwards from the rocker. The rear end of thecam 24 projects into the switch housing 1 through an open end thereofand is tapered in two stages to terminate at an edge- 27. Those parts 28of the cam 24 having the first stage of the taper are such that when therocker 17 is in either of its end positions one of these parts 28 of thecam abutsthe inside of the switch housing 1 of the body. Those parts 29of the cam 24 having the second stage of the taper engage the centralpart of a cylindrical metal roller 30 which constitutes the contactmember of the switch.

The axis of the contact member 30 is at right angles to the axis of thetubular switch housing 1, and the contact member extends through alignedslots in parallel arms 31 of a locator 32 which also includes a bodyuniting the arms and a spigot 33 which extends rearwards from the bodydown the switch of the locator32, and one end of the spring 34 abuts thebody of the locator 32 while the other end of the spring 34 abuts theend plate 2 of the switch body.

When the switch is in its ofi position (FIG. 3) the locator 32 abuts oneside of the switch housing 1, while the cam 24 abuts the opposite sidethereof. The cam 24 also engages the contact member 30 between the arms31 of the locator 32. If the rocker 17 is then moved to its otherposition (FIG. 4) the cam 24 first moves the contact member 30 towardsthe rear of the switch against the action of the spring 34; then, whenthe rear edge 27 of the cam 24 passes the center-line of the contactmember 30, this member is moved by the spring 34 towards the other sideof the switch housing 1. This movement of the contact member 30terminates when the contact member 30 engages two spaced parallelcontact plates 35 disposed immediately outside the arms 31 of thelocator 32.

Tha main planes of the contact plates 35 are parallel with each otherand with the axis of the switch'housing 1 and are at right angles to theaxis of the contact member 30. Each contact plate 35 includes aparallelsided strip abutting the side of the switch housing andterminating at its forward end in a stop 36 which projects towards theopposite side of the housing. The edge of the stop 36 is in the shape ofa 90 concave arc, and the arrangement is such that the spring 34 urgesthe contact member 30 onto the stops 36 when the switch is in its onposition. Thus there is relatively extensive contact between the contactmember 30 and the contact plates 35 when the switch is on. The extent ofthe contact may increase with use as the contact member 30 beds into thestops 36.

When the rocker 17 is rocked from the on position to the off positionthe part 29 of the cam with the second stage taper engages the contactmember 30 and initially moves it towards the rear of the switch againstthe action of the spring 34; then, when the rear edge 27 of the cam 24passes the center-line of the contact member 30, this member is moved bythe spring 34 to the off position. During the rearward movement of thecontact member 30 the member may roll in the locator 32, or it may rubagainst the contact plates 35 or may do both. In each instance, however,there is a tendency for the contacting surfaces either to be replaced byfresh ones or to be cleaned. The actual movement of the contact member30 depends on a large extent on the size of the slots in the arms 31 ofthe locator 32, and these may be such as to permit free rotation of themember 30, restricted rotation, or no rotation at all.

In an alternative arrangement the arms 31 of the locator 32 are formedwith holes rather than slots to receive the contact member 30.

The contact plates 35 extend through parallel slots 37 in the end plate2 of the switch housing 1, pass on opposite sides of the bosses 14 andterminate in pierced terminal blades 38 suitable for snap engagement.with complementary connectors of the well-known kind. One half of eachof the slots 37 in the end plateis formed in one shell 9, while theother half is formed in the other shell 9. The contact plates 35 areintroduced into the slots 37 during assembly of the shells 9, and theplates 35 and shells 9 are so shaped than when the moving body isassembled the plates are prevented from moving relatively to the body.

When the switch is in its on position the contact portion 26 engages oneend of a conductive strip 39 mounted on the body of the switch, but whenthe switch is in its off position the contact portion 26 is separatedfrom the conductive strip 39. One end part of the conductive strip liesagainst the front surface of the back plate 4 of the rocker housing 3,extending from one end of that surface to a position adjacent to theswitch housing 1. The strip 39 then passes a slot 40 in the back plate 4and extends along the outer surface of the switch housing 1 towards theend plate 2 thereof. The outer surface of the switch housing 1 is formedwith a shallow rectangular groove 41 which can receive that part of theconductive strip 39. In its normal, unstressed state that part of thestrip 39 alongside the switch housing 1 is bowed outwards so that-onlyits ends are located in the groove 41. When the switch is mounted in itsposition of use, however, the strip 34 is at least partially flattenedinto the groove is shown in FIGS. 3 and 4 and engages the metal panel 8through which the switch housing extends, or the securing nut 6, or someother adjacent electrically conductive part. If by any chance the panel8 is made of a non-conductive material the strip 39 may contact a metalring (not shown) disposed on the switch housing 1 immediately behind thepanel 8. The hole in the ring may conveniently be of the same diameteras that in the panel.

The ring is formed with three outwardly directed integral fingersclosely adjacent to one another, the central one being bent somewhatfrom the plane of the ring and of the outer fingers. In use a earthingwire can be passed between the center and outer fingers and the fingerscan be turned over, crimped or otherwise deformed to trap the wire inplace and make good electrical contact with it.

Each shell 9 is formed with an outwardly directed integral fin (notshown) lying substantially in the plane along which the shells abut eachother, the fins extending on opposite sides of the switch housing 1.Each fin extends from a position adjacent to the end plate 2 of theswitch housing 1 to a position adjacent to the screw-thread on theswitch housing 1. Each fin extends outwards to an extent substantiallyequal to the maximum diameter of the screw-thread. In manufacture theretaining nut 6 is pushed onto the unthreaded rear portion of the switchhousing 1 and is frictionally held in place by the fins. It may alsoserve to retain in place a ring of the kind described in the lastpreceding paragraph. It is intended that the person installing theswitch should pull the nut 6 from the housing ll, and the ring if suchis present, and then pass the housing 1 through the hole 7 in a mountingpanel 8 or the like, replace the ring, if any, and replace and screw upthe nut 7 to hold the switch in place. Use of the fins avoids the needfor the manufacturer to screw the nut 6 onto the switch housing duringassembly and for the person installing the switch to unscrew it againbefore mounting the switch in position. If desired the fins may betapered towards the nut to be pushed readily onto the fins. The use offins, or like resilient components, in this manner is not restricted toswitches embodying the invention but is of general application.

In order to ensure that the end of the strip 39 inside the rockerhousing 3 does not move when the outer end part of the strip isflattened, the inner end portion is anchored. There may be parallel ribsprojecting from the back plate and defining between them a slot forreceiving the strip 39; parts of the ribs near the switch housing may bedeformed after the strip 39 is in place so as to overlap the margins ofthe strip 399 and thus anchor it in place.

When the switch is in use in a motor vehicle it may be used foroperating an accessory such as a spot-light. In this case one of thecontact plates 35 is connected to the live terminal of the battery andthe other is connected by way of the accessory to earth. The conductivestrip 39 which extends outside the switch is also earthed. When theswitch is in its on position the contact member 30 engages both ofthecontact plates 35 thus enabling current to pass through the accessory.At the same time current flows from the live contact member 30 to thecap 19 of the bulb 18, while the end contact 23 of the bulb is earthedthrough the U-shaped contact band 26 and the external conductive strip39. The bulb 18 is thus lit when the accessory is operative.

In an alternative form of switch (not illustrated) the body is made as aunitary moulding in a simple two-part mould, the parts separating in adirection parallel with the axis of the switch housing 1. One part ofthe mould defines the outside of the body, and includes portions whichdefine the slots 37 in the end plate 2 of the housing 1 to receive thecontact plates 35. Other portions of this part of the mould extendthrough the back plate4 of the rocker housing 3 so as to define therecesses 23 for engagement by the rocker trunnions 21. These latterportions may break into the thread on the outside of the switch housing1.

The rocker 17 is also slightly modified. The end faces of the trunnions21 are inclined so that during assembly the rocker 17 can be pushed intothe rocker housing 3, and the inclined faces can progressively urge theopposite sides of the peripheral flange 5 apart until the trunnions 21become aligned with the recesses 23 whereupon the sides of the flange 5snap inwards to retain the rocker 17 in position.

The side edges of the contact plate 35 are stepped inwards towards therear and engage shoulders on the housing which prevent undesiredrearward movement of the plates. During assembly of the switch theblades 38 of the contact plate 35 are pushed through the slots 37 fromthe interior of the switch housing 1. In order to retain them inposition each plate 35 is formed with a circular hole, a little in frontof the end plate 2 of the switch housing 1. An associated lug on thehousing snaps into each hole but is rather less long than the thicknessof the plate. The inner faces of the lugs may be tapered to assist thepassage of the plates but to prevent their withdrawal. In an alternativemethod of retaining the contact plate 35 in position the holes in theplates are replaced by saw-tooth-shaped notches in the edges of theplates, a little in front of the end plate of the switch housing, whilethe lugs are replaced by complementary saw-tooth-shaped projections inthe switch housing. These permit insertion of the plates but preventtheir withdrawal.

Another embodiment of the switch is not iluminated, the operating cam 24and trunnions 21 being moulded integrally with the rocker 17.

The switch mechanism described in the foregoing description is of thekind which is also described in British Patent No. 1,193,072 of GeorgeTurnock Limited and Henry Charles Shelton.

I claim:

1. A rocker switch comprising a rocker housing, a cylindrical switchhousing extending from said rocker housing, the external diameter ofsaid cylindrical switch housing being less than any outside dimension ofsaid rocker housing in a plane normal to the axis of saidcylindrical-switch housing, switch mechanism housed in said cylindricalswitch housing, and a rocker mounted at least partially within saidrocker housing and manually operable to operate said switch mechanism,and wherein said cylindrical switch housing and said rocker housing areformed as integral parts of a switch body comprising a first mouldedshell and a second moulded shell, said shells lying principally onopposite sides of a plane including the axis of said cylindrical switchhousing.

2. A rocker switch in accordance with claim 1 wherein a first portion ofone shell adjacent to said plane including the axis of said cylindricalswitch hous- 'ing is formed with a recess extending from said plane, a

second portion of said one shell adjacent to said plane and disposedopposite said first portion is formed with a recess extending from saidplane, and in the assembled switch body said recesses are closed byportions of the other said shell to define a pair of opposed orifices insaid rocker housing, trunnions forming pivots for said rocker beingjournalled in said orifices.

3. A rocker switch in accordance with claim 2 wherein said orificesextend into the other of said shells.

4. A rocker switch in accordance with claim 1 including a strap mouldedintegrally with said shells, said shells being moulded as a matched pairconnected endto-end by said strap.

5. A rocker switch in accordance with claim 1 wherein at least a portionof said cylindrical switch housing is externally screw-threaded.

6. A rocker switch in accordance with claim 5 wherein said cylindricalswitch housing is provided with a first outwardly directed fin and asecond outwardly directed fin in a position diametrically opposed tosaid first fin, said fins extending substantially to the maximumdiameter of the screw-thread along an unthreaded portion of said switchhousing.

7. A rocker switch in accordance with claim 1 wherein said rocker is atleast translucent, a lamp is mounted in said rocker and means areprovided operative to light said lamp when said rocker is in oneposition.

8. A rocker switch in accordance with claim 4 wherein said lampcomprises a bulb having an end contact and a shell contact, a bulbcarrier, a fixed contact located on said switch body, a contact bandhaving a portion in contact with said end contact of said bulb and aportion operative to contact said fixed contact when said rocker is insaid one position, and a contact member carried by said bulb carrier andabutting said shell contact of said bulb, said contact member alsoforming an operating cam of said switch mechanism.

9. A rocker switch in accordance with claim 1 wherein a hole is formedin one of said shells and a pin is provided on the other of said shells,said pin projecting into said hole to locate said shells relative toeach other.

1. A rocker switch comprising a rocker housing, a cylindrical switchhousing extending from said rocker housing, the external diameter ofsaid cylindrical switch housing being less than any outside dimension ofsaid rocker housing in a plane normal to the axis of said cylindricalswitch housing, switch mechanism housed in said cylindrical switchhousing, and a rocker mounted at least partially within said rockerhousing and manually operable to operate said switch mechanism, andwherein said cylindrical switch housing and said rocker housing areformed as integral parts of a switch body comprising a first mouldedshell and a second moulded shell, said shells lying principally onopposite sides of a plane including the axis of said cylindrical switchhousing.
 2. A rocker switch in accordance with claim 1 wherein a firstportion of one shell adjacent to said plane including the axis of saidcylindrical switch housing is formed with a recess extending from saidplane, a second portion of said one shell adjacent to said plane anddisposed opposite said first portion is formed with a recess extendingfrom said plane, and in the assembled switch body said recesses areclosed by portions of the other said shell to define a pair of opposedorifices in said rocker housing, trunnions forming pivots for saidrocker being journalled in said orifices.
 3. A rocker switch inaccordance with claim 2 wherein said orifices extend into the other ofsaid shells.
 4. A rocker switch in accordance with claim 1 including astrap moulded integrally with said shells, said shells being moulded asa matched pair connected end-to-end by said strap.
 5. A rocker switch inaccordance with claim 1 wherein at least a portion of said cylindricalswitch housing is externally screw-threaded.
 6. A rocker switch inaccordance with claim 5 wherein said cylindrical switch housing isprovided with a first outwardly directed fin and a second outwardlydirected fin in a position diametrically opposed to said first fin, saidfins extending substantially to the maximum diameter of the screw-threadalong an unthreaded portion of said switch housing.
 7. A rocker switchin accordance with claim 1 wherein said rocker is at least translucent,a lamp is mounted in said rocker and means are provided operative tolight said lamp when said rocker is in one position.
 8. A rocker switchin accordance with claim 4 wherein said lamp comprises a bulb having anend contact and a shell contact, a bulb carrier, a fixed contact locatedon said switch body, a contact band having a portion in contact withsaid end contact of said bulb and a portion operative to contact saidfixed contact when said rocker is in said one position, and a contactmember carried by said bulb carrier and abutting said shell contact ofsaid bulb, said contact member also forming an operating cam of saidswitch mechanism.
 9. A rocker swiTch in accordance with claim 1 whereina hole is formed in one of said shells and a pin is provided on theother of said shells, said pin projecting into said hole to locate saidshells relative to each other.